Motor hall wire harness PCB board pad sorting structure, rapid test fixture and test device

Abstract

The application discloses a motor Hall wire harness PCB pad sequencing structure and a rapid test fixture and a test device. The pad sequencing structure comprises six groups of pads corresponding to VCC, GND, A / B / C signal lines and NTC temperature sensing lines of the welded Hall wire harness, adjacent pads are staggered and arranged in high-low staggered arrangement, the projection spacing is increased, and the risk of tin short circuit is eliminated from the root cause. The test fixture comprises a base platform and a hinged pressure needle platform, the base platform is provided with a detection positioning opening, the pressure needle platform is provided with a spring needle type detection needle head corresponding to each pad, and all lines can be detected at one time by pressing, and a reset spring is arranged to automatically rebound. The test device is integrated with a controller, the detection needle head automatically collects power on-off, phase and temperature line signals, and completes good and bad product determination. The application effectively reduces the welding failure rate, realizes instant detection of welding quality, greatly improves the detection efficiency, and has simple structure and low cost.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to a PCB board pad arrangement structure for a motor Hall effect harness, a rapid testing fixture, and a testing device. Background Technology

[0002] In existing technologies, the standard configuration of a conventional brushless motor Hall effect harness consists of five functional cables: Hall effect power supply positive (VCC), power ground (GND), A-phase position signal line, B-phase position signal line, C-phase position signal line, and NTC temperature sensor line, used to implement the motor overheat protection function. Currently, the industry's motor Hall effect PCB boards generally adopt a horizontal dense pad layout structure, with the five sets of functional pads arranged horizontally in a straight line. Due to the limitations of the internal installation space of the motor and the miniaturization design of the PCB board, the spacing between each pad is extremely small, the layout is compact and dense, the soldering operation space is narrow, and the requirements for assembly and soldering processes and the skill level of operators are extremely high.

[0003] Currently, the connection between Hall effect harnesses and PCB pads is generally achieved through manual soldering. However, this process has many inherent drawbacks due to limitations imposed by production conditions. Because workshop workers vary in their soldering skills, hand stability, and ability to control the amount of solder applied, problems such as excessive solder, solder dripping, and accidental contact between the soldering iron tip and adjacent pads are prone to occur during manual soldering. This can lead to defects such as solder bridging and short circuits between adjacent pads. Among these, short circuits between the VCC power supply pad and the GND ground pad, short circuits between the signal pads and the power supply pads, and short circuits between multi-phase signal lines are the most frequent. These short circuits can directly cause the Hall sensor chip to burn out, resulting in abnormal Hall signal output. Ultimately, this leads to quality problems such as motor starting jitter, weak operation, abnormal start / stop, and malfunction, significantly increasing the product defect rate.

[0004] Meanwhile, in the existing production process, the problem of poor Hall welding cannot be detected quickly and immediately at the welding station. Without the means of pre-inspection, defective products will directly flow into the subsequent whole machine testing process. Faults can only be detected through the electrical testing of finished products at the back end. This not only causes waste of semi-finished materials and increases labor rework costs, but also seriously affects the overall production cycle and yield of the production line, thus restricting the efficiency of mass production.

[0005] Furthermore, existing electrical testing methods for Hall effect harnesses have significant drawbacks, including cumbersome testing procedures and low operational efficiency. Currently, the industry's mainstream testing methods fall into two categories: the first is the bare wire stripping test, where operators must strip the insulation from the ends of five Hall effect cables one by one, then connect them to the terminals of the testing equipment to complete the electrical test. After testing, the harness insulation structure must be reorganized, making the operation cumbersome and time-consuming. The second is the plug-in testing method, which requires pre-assembling a female plug at the Hall effect harness end, then connecting the female plug to the male plug of the testing equipment for testing. This method adds an extra plug assembly step, resulting in redundant procedures and high material costs.

[0006] Both of the above traditional testing methods rely on manual alignment, insertion, and reset operations. This involves a large amount of manual intervention, is time-consuming, and has low efficiency, making it unsuitable for the needs of automated and efficient mass production. In addition, manual operation is prone to problems such as incomplete insertion, missed detection, and false detection, which further affects the accuracy of product quality inspection and production efficiency.

[0007] In summary, the existing manufacturing process for motor Hall effect wires suffers from technical defects such as easy short circuits during welding, high defect rate, high rework cost, delayed fault detection, cumbersome testing procedures, and low testing efficiency. There is an urgent need to design a simple, short-circuit-proof, convenient, and efficient assembly and testing solution for motor Hall effect wires to address the many shortcomings of the existing technology. Summary of the Invention

[0008] Based on this, it is necessary to provide a motor Hall harness PCB board pad arrangement structure, a rapid testing fixture, and a testing device to address the existing technical problems.

[0009] To address the problems of existing technologies, this invention discloses a PCB board pad arrangement structure for a motor Hall effect harness, comprising six sets of pads for corresponding soldering of the positive power supply line (VCC), the power ground line (GND), the A-phase position signal line, the B-phase position signal line, the C-phase position signal line, and the NTC temperature sensing line of the Hall effect harness; the six sets of pads are arranged horizontally, and adjacent sets of pads are arranged in a staggered, alternating pattern, which increases the projection distance between adjacent pads and sets the edges of the pads to be staggered, thus avoiding the risk of short circuits caused by dense arrangement on the same straight line.

[0010] In one embodiment, a solder mask layer is provided in the gap area between the pads on the PCB board.

[0011] In one embodiment, the solder resist layer is ink.

[0012] This invention also discloses a rapid testing fixture for motor Hall effect harnesses, including a base platform and a pressure pin platform hinged above the base platform. The pressure pin platform is provided with a PCB board pad arrangement structure for motor Hall effect harnesses as described in any one of claims 1 to 3. The base platform has a detection positioning port for positioning and placing the motor Hall effect harness. Multiple sets of detection pins are vertically inserted on the end face of the pressure pin platform facing the base platform. The multiple sets of detection pins are arranged according to the layout of the PCB board pad arrangement structure for motor Hall effect harnesses. When the pressure pin platform is pressed down, the detection pins accurately connect and conduct the corresponding cables of the Hall effect harness, thereby realizing the electrical detection of the Hall effect harness.

[0013] In one embodiment, the plurality of detection needles are arranged horizontally, and adjacent groups of detection needles are arranged in a staggered, alternating pattern.

[0014] In one embodiment, the width of the detection positioning port is the same as the width of the Hall harness, so that the Hall harness can be inserted and lateral positioning can be achieved.

[0015] In one embodiment, a reset spring is also included. The reset spring is vertically installed between the same-side ends of the base platform and the pressure needle platform. The two ends of the reset spring are fixedly connected to the base platform and the pressure needle platform, respectively, to realize automatic springback reset after the pressure needle platform is pressed down for detection.

[0016] In one embodiment, the detection positioning port is provided with a plurality of perforations, each of which is matched to the passage of a detection needle.

[0017] This invention also discloses a motor Hall effect harness testing device, including a controller for signal acquisition, logic judgment, and data output, and the aforementioned rapid testing fixture for motor Hall effect harnesses. Each set of detection probes in the testing fixture is electrically connected to the controller. The controller acquires the power supply on / off, phase signal, and temperature circuit on / off signal of the Hall effect harness through the detection probes, thereby determining whether the Hall effect harness is a good or bad product. Compared with the prior art, the present invention has the following advantages: 1. Significant short-circuit prevention effect in soldering: By designing the PCB pads with a staggered arrangement of high and low pads, the vertical height difference between adjacent pads is formed, and the horizontal projection distance is significantly increased. This effectively blocks the physical path of solder flowing and spreading between adjacent pads, eliminating the risk of short circuits caused by solder bridging and solder bridges from the structural source, and greatly reducing the soldering defect rate.

[0018] 2. Immediate detection of welding defects: With the help of rapid testing fixtures, welding quality can be quickly detected at the welding station without waiting for subsequent whole machine testing. This achieves pre-interception of welding defects, prevents defective semi-finished products from flowing into subsequent processes, reduces material waste and rework costs, and improves production yield and production cycle time.

[0019] 3. Significantly improved testing efficiency: The test fixture adopts a hinged pressure pin platform combined with a spring-loaded pin structure. Operators only need to place the Hall effect harness into the positioning port and press down the pressure pin platform to complete the electrical testing of all six groups of circuits at once. The testing process only takes a few seconds. Compared with the traditional bare wire stripping test and plug docking test methods, the testing efficiency is increased several times. Moreover, there is no need to strip the cable insulation layer or assemble the plug separately, saving cumbersome procedures and consumable costs.

[0020] 4. Simple operation and reduced reliance on manual labor: The fixture adopts the operation method of positioning port positioning, hinge pressing and spring reset, which eliminates the need for manual one-by-one alignment and insertion, reduces the operation skill requirements, reduces the risk of human error and missed detection, and improves the consistency and reliability of detection.

[0021] 5. Automated judgment and data traceability: The testing device integrates a controller to realize automatic acquisition of detection signals, automatic logic judgment, and automatic output of results. The test results can be uploaded to the host computer or production management system through the communication interface to realize the traceability management of test data, which is conducive to the statistical analysis of production quality data and continuous process improvement.

[0022] 6. Simple structure and low cost: The PCB pad arrangement structure can achieve short circuit protection simply by adjusting the pad layout, without increasing material costs; the test fixture has a simple structure, few parts, and low manufacturing and maintenance costs, making it suitable for mass production applications. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the pad arrangement of the PCB pad sorting structure for the motor Hall harness provided in an embodiment of the present invention; Figure 2 A three-dimensional structural schematic diagram of the motor Hall harness rapid testing fixture provided in an embodiment of the present invention; Figure 3 for Figure 2 The side view shown; Figure 4 for Figure 2 The front view shown; Figure 5 A system block diagram of the controller for the motor Hall harness testing device provided in an embodiment of the present invention; Figure 6 A three-dimensional structural schematic diagram of the controller of the motor Hall harness testing device provided in an embodiment of the present invention; Figure 7 This is a schematic diagram of the application of the motor Hall harness PCB pad arrangement structure of the present invention to a motor.

[0024] The annotations in the attached figures are explained as follows: 1. First pad (corresponding to Hall power supply positive line VCC); 2. Second pad (corresponding to power ground line GND); 3. Third pad (corresponding to phase A position signal line); 4. Fourth pad (corresponding to phase B position signal line); 5. Fifth pad (corresponding to phase C position signal line); 6. Sixth pad (corresponding to NTC temperature sensor line); 7. Solder mask layer; 10. Base platform; 11. Detection positioning port; 20. Pressure needle platform; 21. Detection needle mounting hole; 22. Detection needle; 221. Needle shaft; 223. Needle tube; 30. Hinge mechanism; 40. Return spring; 51. Screen assembly; 52. Buzzer alarm; 60. Controller; 61. Microprocessor unit; 62. Signal acquisition circuit; 63. Drive circuit; 64. Communication interface. Detailed Implementation

[0025] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention.

[0026] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0027] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0028] Example 1: PCB board pad arrangement structure for motor Hall effect harness like Figure 1 and Figure 7As shown, this embodiment provides a PCB board pad arrangement structure for a motor Hall harness, including six groups of pads: first pad 1 (corresponding to the positive power supply line VCC), second pad 2 (corresponding to the power supply ground line GND), third pad 3 (corresponding to the A-phase position signal line), fourth pad 4 (corresponding to the B-phase position signal line), fifth pad 5 (corresponding to the C-phase position signal line), and sixth pad 6 (corresponding to the NTC temperature sensing line).

[0029] Six sets of pads are arranged sequentially along the horizontal direction of the PCB board. Pad 1, pad 3, and pad 5 are located at the first horizontal height H1, while pad 2, pad 4, and pad 6 are located at the second horizontal height H2. There is a height difference between the first horizontal height H1 and the second horizontal height H2.

[0030] Through the above staggered arrangement design, the spacing between the pad edges in the horizontal projection direction is increased by about 40% to 60% compared with the traditional straight arrangement.

[0031] Furthermore, a solder resist layer 7 is provided in the gap area between the pads on the PCB board. The solder resist layer 7 uses solder resist ink. The solder resist layer 7 covers all non-soldered areas between the pads, forming a physical isolation barrier and further enhancing the anti-solder bridging effect.

[0032] In this embodiment, the PCB board pad arrangement structure, due to the staggered height of adjacent pads during assembly and soldering, prevents solder from flowing to adjacent pads even if the soldering iron tip is slightly over-applied or misaligned when soldering a particular pad. This effectively avoids solder bridging and short circuits. Simultaneously, the staggered arrangement increases the soldering operation space, making it easier for operators to see and accurately align each pad, thus reducing the difficulty of the soldering operation.

[0033] Example 2: Rapid Testing Fixture for Motor Hall Harnesses like Figures 2 to 4 As shown, this embodiment provides a rapid testing fixture for motor Hall effect harnesses, including a base platform 10 and a pressure pin platform 20.

[0034] The base platform 10 is a rectangular plate structure made of aluminum alloy, which has good structural strength and rigidity. The middle part of the base platform 10 is hinged to the middle part of the pressure needle platform 20 through a hinge mechanism 30. The hinge mechanism 30 includes a hinge shaft and a hinge seat, which allows the pressure needle platform 20 to rotate up and down in a vertical plane around the hinge shaft.

[0035] The upper surface of the base platform 10 is provided with a detection and positioning port 11. The width of the detection and positioning port 11 is the same as the width of the Hall wire harness, so that the Hall wire harness can be inserted and laterally limited and positioned.

[0036] Multiple sets of detection probes are vertically inserted on the end face of the pressure platform facing the base platform. The pressure platform features a PCB board pad arrangement structure for the motor Hall harness. The multiple sets of detection probes are arranged according to this PCB board pad arrangement structure. This layout allows for miniaturization of the motor Hall harness and reduces the likelihood of solder bridging. When the pressure platform is pressed down, the detection probes precisely align with and conduct the corresponding cables of the Hall harness, achieving electrical testing of the Hall harness. The detection probe 22 is a probe head, including a needle shaft 221 and a needle tube 223. The needle shaft 221 is partially inserted into the needle tube 223. The tip of the needle shaft 221 first contacts the surface of the Hall harness; as pressure continues, the needle shaft 221 pierces the surface sleeve of the Hall harness, establishing electrical connection with the internal wires of each cable. The tail of the needle tube 223 is connected to the signal acquisition circuit of the test device controller via a wire (not shown).

[0037] At least one set of return springs 40 is provided between the base platform 10 and the pressure needle platform 20 on the same side. Preferably, two sets of return springs 40 are provided in this embodiment, symmetrically arranged at the front and rear ends of the base platform 10. Each return spring 40 is a compression spring, with its upper end fixedly connected to the lower surface of the pressure needle platform 20 and its lower end fixedly connected to the upper surface of the base platform 10. When the operator presses down on the pressure needle platform 20, causing it to flip downwards to complete the test, and then releases the external force, the return spring 40 extends under its own elastic force, pushing the pressure needle platform 20 upwards to return to its initial open position, thus achieving automatic reset.

[0038] The working process of the test fixture in this embodiment is as follows: Step S1: The operator holds and flips the pressure needle platform 20 to the open position (if the fixture is in the closed state, the return spring 40 will automatically keep it in the open position).

[0039] Step S2: Place the welded Hall harness into the detection and positioning port 11 of the base platform 10 and fix it in place.

[0040] Step S3: The operator presses down the needle platform 20 and flips it downwards. The needle shaft 221 of the detection needle 22 contacts and pierces the Hall wire harness. The six sets of detection needles 22 simultaneously make contact with the six cables of the Hall wire harness.

[0041] Step S4: The controller collects signals from each line through the detection probe 22, executes the detection logic program, and completes the determination of good or bad products.

[0042] Step S6: The operator releases the hand, and the reset spring 40 automatically pushes the pressure needle platform 20 back to the open position, completing one testing cycle.

[0043] The entire detection cycle takes about 3 to 5 seconds, which is 6 to 10 times more efficient than the 30 to 60 seconds of the traditional detection method.

[0044] Example 3: Motor Hall Harness Testing Device like Figure 6 As shown, this embodiment provides a motor Hall harness testing device, including a controller 60 and the motor Hall harness rapid testing fixture described in Embodiment 2.

[0045] The controller 60 includes a microprocessor unit 61, a signal acquisition circuit 62, a drive circuit 63, and a communication interface 64.

[0046] The input terminal of the signal acquisition circuit 62 is electrically connected to the six sets of detection probes 22 of the test fixture via wires, and is used to acquire the on / off status signals and resistance parameters of each line. The signal acquisition circuit 62 includes a constant current source module, a voltage divider sampling module, and an analog-to-digital converter (ADC) module. The constant current source module outputs a constant current to the line under test, the voltage divider sampling module acquires the voltage drop on the line under test, and the ADC module converts the analog voltage signal into a digital signal and sends it to the microprocessor unit 61.

[0047] The microprocessor unit 61 uses an ARM Cortex-M series microcontroller and has a pre-programmed detection logic program. The microprocessor unit 61 receives the digital signal sent by the signal acquisition circuit 62, makes a judgment according to the pre-programmed detection logic, and outputs a good or bad product judgment signal.

[0048] The driving circuit 63 includes an indicator light driving circuit and a buzzer driving circuit, which are electrically connected to the screen assembly 51 and the buzzer alarm 52, respectively, and drive the corresponding indicator light and buzzer to work according to the judgment result signal output by the microprocessor unit 61.

[0049] The communication interface 64 uses an RS232 serial port or a USB interface to connect to a host computer or production management system, upload test data to the production management database, and realize the traceability management of test data.

[0050] like Figure 7 As shown, the detection logic flow of this embodiment is as follows: Step S101: The device is powered on and initialized. The microprocessor unit 61 loads the detection program, and each module enters the standby state.

[0051] Step S102: Detect whether the pressure needle platform 20 is pressed down to the correct position. The pressing state of the pressure needle platform 20 is detected by a limit switch located on the base platform 10. When a pressing signal is detected, proceed to step S103.

[0052] Step S103: The signal acquisition circuit 62 sequentially or simultaneously acquires the electrical signals of the six sets of detection needles 22.

[0053] Step S104: Microprocessor unit 61 determines whether the resistance value between VCC and GND is within the normal range (e.g., 1kΩ to 100kΩ). If the resistance value is close to zero (less than 10Ω), it is determined that VCC-GND is short-circuited, and proceeds to step S109; if the resistance value is close to infinity (greater than 1MΩ), it is determined that the power supply line is open-circuited, and proceeds to step S109; otherwise, proceeds to step S105.

[0054] Step S105: Microprocessor unit 61 determines whether there is a short circuit between the signal lines of phase A, phase B, and phase C and VCC and GND, respectively, and whether there is a short circuit between the signal lines of each phase. If any short circuit is detected, proceed to step S109; otherwise, proceed to step S106.

[0055] Step S106: The microprocessor unit 61 determines whether the resistance value between the NTC temperature sensing line and GND is within the normal resistance range of the NTC sensor (e.g., 5kΩ to 50kΩ, depending on the NTC sensor specifications). If the resistance value is abnormal, proceed to step S109; otherwise, proceed to step S107.

[0056] Step S107: All test items are deemed normal, and the microprocessor unit 61 outputs a good product judgment signal.

[0057] Step S108: The drive circuit 63 sends a good product signal to the screen component 51 for display, the buzzer does not sound, the communication interface 64 uploads the good product detection data, and one detection is completed.

[0058] Step S109: If an abnormal item is detected, the microprocessor unit 61 outputs a defective product judgment signal and records the defect type information.

[0059] Step S110: The drive circuit 63 sends a defective product signal to the screen component 51 for display, the buzzer alarm 52 sounds an alarm, and the communication interface 64 uploads the defective product detection data (including the defect type), completing one detection.

[0060] The testing device in this embodiment can be deployed directly at the welding station. After the operator completes the Hall effect harness welding, the Hall effect harness is immediately placed into the testing fixture for testing. The test results can be obtained within 3 to 5 seconds, enabling immediate interception of welding defects. At the same time, the test data is automatically uploaded to the production management system through the communication interface. Managers can monitor the welding quality trend in real time and adjust the welding process parameters in a timely manner to achieve closed-loop control of production quality.

[0061] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A PCB board pad arrangement structure for a motor Hall effect harness, characterized in that: It includes six sets of pads for corresponding welding Hall effect harnesses: positive power supply line (VCC), ground power supply line (GND), A-phase position signal line, B-phase position signal line, C-phase position signal line, and NTC temperature sensor line. The six sets of pads are arranged horizontally, and adjacent sets of pads are arranged in a staggered manner to increase the projection distance between adjacent pads and to offset the edges of the pads, thereby avoiding the risk of short circuit caused by dense arrangement on the same straight line.

2. The PCB board pad arrangement structure for the motor Hall harness according to claim 1, characterized in that, A solder resist layer is provided in the gap area between the pads on the PCB board.

3. The PCB board pad arrangement structure for the motor Hall harness according to claim 2, characterized in that, The solder resist layer is ink.

4. A rapid testing fixture for motor Hall effect harnesses, comprising a base platform and a pressure pin platform hinged above the base platform, characterized in that: The pressure pin platform is provided with the motor Hall harness PCB board pad arrangement structure as described in any one of claims 1 to 3; the base platform is provided with a detection positioning port for positioning and placing the motor Hall harness; multiple sets of detection needles are vertically inserted on the end face of the pressure pin platform facing the base platform, and the multiple sets of detection needles are arranged according to the layout of the motor Hall harness PCB board pad arrangement structure. When the pressure pin platform is pressed down, the detection needles accurately connect and conduct each cable of the corresponding Hall harness, thereby realizing the electrical detection of the Hall harness.

5. The rapid testing fixture for motor Hall effect harnesses according to claim 4, characterized in that, The multiple sets of detection needles are arranged horizontally, and adjacent sets of detection needles are arranged in a staggered, alternating pattern.

6. The rapid testing fixture for motor Hall effect harnesses according to claim 4, characterized in that, The width of the detection and positioning port is the same as the width of the Hall harness, so that the Hall harness can be inserted and lateral positioning can be achieved.

7. The rapid testing fixture for motor Hall effect harnesses according to claim 4, characterized in that, It also includes a reset spring, which is vertically installed between the same side ends of the base platform and the pressure needle platform. The two ends of the reset spring are fixedly connected to the base platform and the pressure needle platform respectively, so as to realize the automatic springback reset after the pressure needle platform is pressed down for detection.

8. The rapid testing fixture for motor Hall effect harnesses according to claim 4, characterized in that, The detection positioning port has several through holes, and each through hole is matched to the passage of each detection needle.

9. A motor Hall effect harness testing device, comprising a controller for signal acquisition, logic judgment, and data output, characterized in that: It also includes a rapid testing fixture for motor Hall harnesses as described in any one of claims 4 to 8, wherein each set of detection probes of the testing fixture is electrically connected to the controller, and the controller collects the power supply on / off, phase signal, and temperature circuit on / off signal of the Hall harness through the detection probes to complete the determination of good and bad Hall harness welding products.

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